MARKET SOLUTIONS AUTOMOTIVE

MARKET SOLUTIONS AUTOMOTIVE MARKET SOLUTIONS

Automotive Market Solutions TPC Wire & Cable Corp. is a leading supplier of high-quality, high-performance wire, cable, connectors, and assemblies designed and engineered to withstand harsh industrial environments. We know how critical it is that your cables and connectors be able to survive abuse from flexing, impact, abrasion, extreme temperatures, and caustic chemicals. TPC products solve the most difficult application problems and outlast ordinary cable 10:1, reducing your downtime, labor, and overall costs. Tier-1 Auto Parts Supplier s Servo Motor Cable Doesn t Cut It Problem A Tier-1 automotive supplier of underbody structural parts was experiencing problems with the power cable for its servo motors and needed to replace it every 1.5 months. The cable would be cut by parts, fail, and sometimes blow out the servo motors to the tune of $3,000+ each. The cost to replace the cable was $546 in product and labor expenses each and every time. Solution The TPC representative recommended Super-Trex Reduced Diameter Control Cable customized and strengthened with aramid. Already designed with a high strand count and construction that provides long life in dynamic flexing applications, the thermoplastic elastomer (TPE) jacket was enhanced with an aramid fiber vest to yield exceptional strength and cut-through resistance. The customized cable solution would also provide excellent protection against oil and most industrial chemicals. Result TPC s Super-Trex Reduced Diameter Control Cable with aramid over-braid was installed on all 6 servo motor units. After 1 year in use, the cables were holding up well against cutting hazards. After 3 years in use, again without failure, it was determined the customer was able to avoid 144 hours in downtime and the total cost in products and labor for TPC s solution was just $1,357 compared to the $13,104 the customer would ve spent replacing cable every 6 weeks across 6 units over the course of 36 months. Ultimately, TPC was able to save the customer $11,747 in expenses and delivered a 138-hour increase in production time. Since then, in response to customer needs, TPC has introduced Trex-Onics Servo Motor Cable, color-coded orange and specifically designed to protect motors from damage by reducing noise issues while extending conductor life in dynamic applications. CURRENT PRODUCT VS. TPC PRODUCT Current Product TPC Product $14,000 $12,000 $10,000 $8,000 $6,000 $4,000 $2,000 $0 $8,064 $5,040 $13,104 $1,147 $1,357 $210 Product Cost + Labor Cost = Overall Cost Source: TPC Cost Value Analysis Report #1361 Total Saving in Materials & Labor = $11,747 Production Increase = 138 Hours

TPC Products Solve Problems in Automotive Applications POWERTRAIN, TRANSMISSION & ENGINE Machining / Metalworking Tool Making Low Pressure Die Casting Aluminum Casting Forging of Cranks & Camshafts High Pressure Diecasting Melting Furnace Engine Assembly CNC Machine Drive System Material Handling Equipment Portable Welding Units Pendant Portable Power Tooling & Valves Prox Sensor, Signal & Control Drive Cable Assemblies Engine Test Harness Valve Control Manifolds & Sand Molding Material Handling Equipment Robots Casting Machines & Pendant Stations Die Blocks, Light Curtains Safety Switches, Photo Eyes, Sensors Thermocouples Temperature & Measuring Equipment High Temp. Power and I/O Motors Material Handling Equipment Robots Robot Handling Equipment, Air Hoses, Electrical Cable, Hydraulic Cable Cranes & Jib Crane Drive Power & Encoder Cable Festoon Systems Material Handling Equipment Robots Engine Test Palitizers Chem-Gard 200 Multi-Conductor Super-Trex SJOO Micro Cord Sets Super-Trex Reduced Diameter Control Cable Trex-Onics Servo Motor Cable Super-Trex & Trex-Onics VFD Cables Trex-Onics Ethernet CAT6A/CAT7A Cable & Assemblies Trex-Onics High-Flex Encoder Cable Super-Trex Power Cables Super-Trex Welding Cable 4 & 8 Button Aluminum Pendants Super-Trex Multi-Conductor P&R Cable Super-Trex Portable Cord 7 Pin Molded Valve Plugs Trex-Onics Indiviually Shielded Pairs Trex-Onics Encoder/Resolver Cable SJOO M12 Cord Set Thermo-Trex 500-K Single / Multi-Conductor Cable Thermo-Trex 2000 Multi-Conductor Cable Super-Trex & Trex-Onics M12 Cord Sets Thermo-Trex Thermo-Couple Extension Wire Chem-Gard Multi-Conductor Cable Super-Trex Type W Portable Power & Automation Cable Trex-Onics Overall Shielded Control Cable Chem-Gard 200 Cable Super-Trex Ultra-Gard Portable Cord Super-Trex Mini Cord Sets DIN Connectors High Temp Mini, Micro & DIN Cord Sets Resistive Thermal Device (RTD) Assemblies

TPC Products Solve Problems in Automotive Applications (continued) ASSEMBLY Trim / Chassis / Final Elevators / Skillet System AGVs Prox Switch, Photo Eyes Hand Tools OBD Test Assembly Drive System Master Power Distribution Drop Festoon Systems Door System Test Fill Line Gas Fill, Radiator Fill, Air Conditioning Fill, Brake Fill Super-Trex Power Cable Super-Trex Reduced Diameter Control Cable Super-Trex (500 MCM / 350 MCM) Power Cable Trex-Onics Overall Shielded C-Flex Multi-Conductor Cable Micro Cord Sets Super-Trex & Trex-Onics VFD Cable Trex-Onics Servo Motor Cable Trex-Onics Shielded Cables Lift Assist Overhead Loaded Cable Carrier Systems Micro / Mini Cord Sets STAMPING / BODY (WELD) Stamping Die Shop Body (Body Weld) Bolster Cables Cable Carriers Reeling Systems Shorting Plugs for Safety Gates Press to Control Panels Die Power & I/O Retractile Cords Material Handler Cable Carrier Portable Power Hand Tools Weld Cable Assemblies 7-Axis Robot Weld Cell Robot Power Control Tool Changer Super-Trex Multi-Conductor P&R Cable Super-Trex Reduced Diameter Control Cable Custom Bolster Cable Trex-Onics Overall Shielded C-Flex Multi-Conductor Cable Trex-Onics Industrial Ethernet Cables DC Micro Cord Sets Super-Trex Power Cables Multi-Run Cable Assemblies Trex-Onics Device-Net Flex-Net Cable Trex-Onics High-Flex Ultra-Coil Retractiles Retractile Quick-Connects Super-Trex Ultra-Gard Portable Cords Cable Stripper Super-Trex Welding Cable Trex-Onics High-Flex Encoder Cable Portable Power & Automation Cable Cable Carrier Super-Trex & Trex-Onics VFD Cable DIN Cord Sets Robot Dress Pack

TPC Products Solve Problems in Automotive Applications (continued) PAINT Paint Shop Phosphate Wash Ecoat & Oven (Motors & Drives, Lights) Sealing & Oven Primer & Oven (Power for Robots, Drive Systems, Prox Switches, Light Curtains) Plastics (Molding) IP69K & Chemical Resistant Cables Grounding Cable Power & I/O Cable High Temp. Micro & Mini Cord Sets Chem-Gard Shielded / Unshielded Cables Thermo-Trex Cord Sets Trex-Onics Industrial Ethernet Patch/Work Area CAT7A Super-Trex Power Cables Trex-Onics & Super-Trex Control Cables Class I Div. I Connectors Thermo-Trex High Temp Cable Thermocouple Extension Wire Aluminum Pendant Box Assembly Trex-Onics High-Flex Encoder Cable Cable Carriers TPC delivers solutions that save labor, material, and downtime costs. We understand how important a high-quality cable is to a cable carrier system, and we have decades of experience with continuous systems, piggy-back systems, dual cable carriers, double-stacked cable carriers and more. The cable package within a carrier system usually makes up the majority of the investment. TPC can provide high-quality, high-flexible cable and integrated chains that are designed for longer-term performance in the automotive plant environment. Upon careful consideration of your carrier dimensions, clearance, travel orientation, bracket configuration and other variables, TPC will design and deliver a complete system that arrives ready for installation, saving you additional labor and downtime.

Custom Design & Engineering Capabilities TPC Wire & Cable Corp. offers custom-engineered products that are designed using specific application and environmental information and built to solve a particular problem for the individual customer. These product solutions represent a unique and valuable service offered by TPC, whose engineers are experienced in the electrical, mechanical, chemical, and industrial engineering disciplines. TPC engineers assemble the critical components of your cable into a final design that delivers a longer-lasting, cost-effective alternative to the constant replacement of ordinary cable. Automotive Stamping Plant Boosts Production & Eliminates Failure with Custom Bolster Cable Problem A large vehicle manufacturing plant in Kentucky was replacing bolster cable on its stamping press every 10-11 months due to failure. The inner conductors would fatigue, deteriorate, and ultimately fail from constant environmental pressures that included flexing, motion, and tension. In addition, the outer jacket was being abraded and cut by metal scrap in the area. Over the course of 32 months, the failures added up to $12,767 in product and labor expenses plus, as a result, the application was down for 53 hours total during that time period. Solution The customer s TPC representative worked with TPC s in-house engineering team to develop a custom solution stemming from the Trex-Onics product line designed for continuous flexing applications in harsh environments. The cable featured an aramid fiber braid embedded into the jacket to add 1,800 lbs tensile strength as well as tinned copper conductors that lengthen flex life in flexing and twisting applications. A polyurethane jacket also served as a superior first line of defense by providing heavy-duty abrasion resistance. Result Checking in on the application 32 months after installation, it was determined that the custom bolster cable still had not yet required repair or replacement. The total cost for product & labor to implement the solution amounted to just $5,145, saving the customer $7,622 and allowing the plant to increase production time by 37 hours. Source: TPC Cost Value Analysis Report #3146 TPC WIRE & CABLE CORP. HEADQUARTERS 9600 VALLEY VIEW RD, MACEDONIA, OHIO 44056 USA 800-521-7935 FAX 866-528-2930 CANADA 800-545-0122 MEXICO 001-877-283-1696 CHILE 1230-020-0229 COLOMBIA 0-1-800-915-7519 PERU 0800-54863 WWW.TPCWIRE.COM WARRANTY AND DISCLAIMER: Seller makes no warranties, express or implied, with respect to this product, and seller disclaims any implied warranties of merchantability or fitness for any particular purpose. Further, seller will not be responsible for any consequential, incidental or indirect damages (including, but not limited to, any loss of profit) from any cause whatsoever. TPC1316 (03/17) PRINTED IN U.S.A. Copyright 2017 by TPC Wire & Cable Corp. All rights reserved. No portion of this publication, whether in whole or in part, can be reproduced without the express written consent of TPC Wire & Cable Corp.